Compressible Rigid Insulation Panel

ABSTRACT

An insulation panel is described that is adapted to be installed between framing members of a building, such as a stud, joist, or rafter. The insulation panel can be installed without the use of fasteners or adhesive. The panel is made of a rigid insulation material such as expanded polystyrene. Grooves are provided along a length of the panel to allow for compression and accommodation of variations in the spacing between framing members.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. §119 of Provisional Application Ser. No. 62/295,261, filed Feb. 15, 2016, which is incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

The invention relates generally to the field of building insulation. More specifically, the invention relates to rigid foam insulation panels.

A variety of products are manufactured and used for insulating a building, including fiberglass batting, loose fill, spray foam, and rigid foam. Loose fill insulation in particular has become a popular choice of material for insulating the attic of a home due to its ease of installation. In this application, the loose fill is installed by blowing the material onto the attic floor below the roof. However, loose fill insulation has lower thermal resistance (R-value) than some competing insulation products. To compensate for the lower thermal resistance, loose fill insulation is installed to a greater depth or thickness than other products. It is not uncommon to find loose fill insulation installed to a depth of 16 inches in a newly constructed home.

Meeting the depth requirement for loose fill insulation becomes problematic in areas of the building with space constraints or that are difficult to access. In particular, the area of the attic where the roof intersects the side wall is an area where loose fill insulation often cannot be installed to a depth sufficient to meet building requirements. Buildings with low pitched roofs have even less space to install sufficient insulation. In addition, the method of installing loose fill insulation by blowing the material into the area to be insulated can lead to inconsistent depths and, therefore, inconsistent insulating properties. Other areas, such as the area between floor joists and a ridge board can be difficult to insulate as well. These problems become exacerbated as local and national building codes are requiring greater R-value insulation to promote energy efficiency.

Due to the difficulties in insulating certain areas, buildings are often left without adequate insulation in a critical area. For example, insufficient insulation at a ridge board can lead to frozen pipes running between the floor joists. Likewise, inadequate insulation of the attic can cause significant problems aside from poor energy performance. In snowy climates, heat escaping from the home through the ceiling can warm the attic space and melt snow that has accumulated on the exterior of the roof. The melted snow can refreeze as it runs down the roof, causing ice dams to form. The ice dams can damage gutters and shingles, while also posing a threat to occupants of the building should the ice become dislodged from the roof. It would therefore be advantageous to develop an insulation product that provided sufficient insulating properties while retaining the easy installation methods preferred by contractors and installers.

BRIEF SUMMARY OF THE INVENTION

According to embodiments of the present invention is a rigid insulation panel than can be quickly installed between framing members of a roof, wall, floor joist, or other structure. By using a material with a relatively high thermal resistance, the insulation panel that can improve thermal performance in difficult to insulate areas or areas with reduced volume. To aid installation, the insulation panel is retained in the cavity between framing members without the use of adhesives or fasteners, relying instead on a friction fit. To accommodate tolerances in the spacing between joists, studs, or rafters, grooves (or cutouts) are formed in the panel, allowing inward compression of the edges of the panel. In some embodiments, longitudinal air channels are provided on a face of the panel for the movement of air when the panel is placed against a surface, such as the underside of a roof.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 depicts a rigid insulation panel according to one embodiment of the present invention.

FIG. 2 is an alternate view of the insulation panel shown in FIG. 1.

FIG. 3 is a profile view of the insulation panel shown in FIGS. 1-2.

FIG. 4 is a top view of the insulation panel according to one embodiment of the present invention.

FIG. 5 shows the insulation panel installed between the rafters of a roof.

FIG. 6 is an alternate view of the panel installed between the rafters of a roof.

DETAILED DESCRIPTION OF THE INVENTION

According to one embodiment of the present invention is an insulation panel for installation in the cavity between framing members of building structure. The insulation panel of the present invention can be made of a variety of rigid insulation materials known in the industry. Suitable insulation materials can include, but are not limited to, expanded polystyrene, extruded polystyrene, impregnated polystyrene, polyurethane, and polyisocyanurate. In one example embodiment, the insulation panel is constructed of Neopor® (BASF) graphite polystyrene-based insulating material due to its improved thermal performance and cost benefits.

As shown in the example embodiment depicted in FIG. 1, the insulation panel is generally rectangular in shape, with the body 100 of the panel defined by longitudinal edges 110, 111 and ends 106, 107. The edges 110, 111 are substantially parallel and are connected by the ends 106, 107, thus forming the perimeter of the panel. When installed, the longitudinal edges 110, 111 contact adjacent framing members of the building structure, which are also generally parallel to each other. However, the insulation panel is not limited to this particular shape and can be manufactured in a variety of shapes for other types of installations. In addition, the rigid foam material is easily cut, making jobsite alterations possible.

The thickness of the panel, which is defined by a bottom surface 102 and a top surface 103, can be varied depending on the intended installation and required thermal resistance (R-value) specified by a builder or homeowner. For example, the thickness can range from a fraction of an inch to several inches. In one example embodiment, the panel is 3.5 inches thick (the depth of 2×4 construction lumber) and provides an R-value of about 15.

While buildings are typically constructed with framing members (such as a stud, rafter, or joist) spaced at specified distances, such as 16 or 24 inches on center, the actual dimension can vary due to lumber and installation inconsistencies. As a result, a spacing distance intended to be 16 inches can, for example, range from 15.5 to 16.5 inches or more. To accommodate the expected variations encountered during installation, the panel is slightly oversized compared to the standard framing dimension, but is compressible across its width through the inclusion of collapsible grooves 101 that are placed through a portion of the depth of the panel. Without the grooves 101, a panel constructed of rigid insulation would have little compliance across its width. As a result, by being oversized but compressible, the panel can be installed across the range of expected framing dimensions without leaving a gap between the framing member and the insulation panel.

As shown in FIG. 1, grooves 101 create a space in the panel that, upon compression, allow a decrease in the overall width of the panel. Stated differently, during installation, an inward force from the framing members on edges 110 and 111 of the panel collapses the grooves 101, thus allowing a reduction in the overall width of the panel. In tighter spaces, the grooves 101 will be compressed to a greater extent, reducing the width of each groove 101. The limit of compression occurs when opposing sides of the grooves 101 begin to touch each other, eliminating the air gap. As a result, the total decrease in width is proportionate to the cumulative size of the air gaps in the grooves 101. For example, if 3 grooves 101 on a panel are each 0.25″ wide, the maximum reduction in width of the panel is about 0.75″. For installations where framing dimensions have greater variability, the number of grooves 101 in the panel or the width of the grooves 101 can be increased. Because the rigid insulation material is resilient, a collapsed groove 101 exerts an outward force as it tries to regain its original shape. This force increases the friction between the edges 110 and 111 of the panel and the framing members against which the edges 110 and 111 abut. As such, the grooves 101 aid the friction fit of the panel during installation.

In the embodiment shown in FIG. 1, a pair of grooves 101 is provided near a first edge 110 of the panel. A second pair of grooves 101 is provided near a second edge 111 of the panel. The first groove 101 of the pair extends from a bottom surface 102 to near a top surface 103. The second groove 101 in the pair is positioned oppositely, extending from the top surface 103 to near the bottom surface 102. The grooves 101 do not traverse through the thickness of the panel, but instead leave a small portion of material at the terminal end of the groove 101, acting as a hinge. On larger panels, such as the one shown in FIG. 1, an additional groove 101 can be provided near the center of the panel since the variation between framing members with larger spacing could be larger as well. Any number of grooves 101 can be used, with total distance of compression increasing as the number of grooves 101 is increased. Moreover, the location of a groove 101 across the width of the panel is not critical to the function of allowing the edges 110 and 111 to compress when installed. FIG. 2 shows that a continuous groove 101 extends along the length of the panel from a first end 106 to a second end 107.

In the embodiment shown in FIGS. 1-2, grooves 101 are provided in pairs positioned on opposing surfaces to help keep the edges 110 and 111 of the panel parallel during compression. If the grooves 101 were only provided on the top surface 103, for example, the panel would tend to curve as the width of the top surface 103 became narrower than the width of the bottom surface 102. By keeping the parallel orientation of the edges 110 and 111, the panel maintains maximum contact with the surfaces of the framing members in a typical installation. With full contact, there is less chance of the panel slipping from its installed position. Further, any gaps between the panel and the framing member would decrease the thermal performance of the insulation.

Referring again to FIG. 2, which is a profile view of the end of the panel, the grooves 101 are S-shaped when viewed from the end. In this embodiment, opposing surfaces of the S-shaped grooves 101 will tend to fold onto each other when the panel is collapsed, progressively tightening the gap from the top to the bottom of the groove 101. See, for example, FIGS. 5-6, which show a panel installed between framing members and the air gap in groove 101 collapsed. With the gap of the groove 101 closed at the edge of the panel, the degradation in thermal performance by the presence of the groove 101 is minimized. In addition, the S-shape does not create a void in the insulation material that is co-linear with the flow of heat, which travels from the bottom surface 102 to the top surface 103. While this example embodiment has been described, alternate groove 101 profiles (i.e. linear, angled, curved, etc.) will function similarly and allow the width of the panel to be compressed.

During installation, the panel can be slid into position between framing members. As shown in the embodiment depicted in FIG. 3, the corners of the panel (or the intersection of the edges 110 and 111 and bottom surface 102) have a chamfer 104 to aid installation. The chamfer 104 is adjacent to the bottom surface 102 when the panel is installed bottom surface 102 first. In this particular embodiment, the insulation panel would be installed in between roof rafters from the topside of the roof—as opposed to being installed from the attic side—before the roof sheathing is installed. This type of installation is often done in pre-fabricated structures. If the insulation panel were installed from the attic side, the chamfer 104 would be formed at the intersection of the top surface 103 and the edges 110 and 111. In these examples, the insulation panel is a type used for roof insulation where the top surface 103 and bottom surface 102 have different features and the panels must be installed in a particular orientation. In alternate embodiments, the chamfer 104 can be adjacent to either the top surface 103 or bottom surface 102, or both.

In embodiments where the insulation panel will be installed on the underside of a roof, air channels 105 are provided, as shown in FIG. 3. The air channels 105 allow for air movement between the panel and the roof from the first end 106 to the second end 107 of the rigid insulation panel. The air channel 105 is comprised of a recess disposed on the top surface 103 of the panel. The shape of the recess can vary depending on the intended installation. For installation against the underside of a roof, the recess is wide, about one inch deep, and runs the length of the panel from the first end 106 to the second end 107. Shingle manufacturers often require free air movement on the underside of the roof to prevent damage to the shingles from excessive heat buildup. If the air is restricted by insulation, shingle manufacturers can void their warranty. In this embodiment where the insulation panel is installed in the roof rafters, additional insulation material can be placed between the bottom surface 102 of the panel and the attic floor.

In the embodiments of the insulation panel shown in FIGS. 1-6, two air channels 105 are provided, each separated by a central rib 109. However, a single air channel 105 or multiple air channels 105 can be disposed on the insulation panel. For example, if the insulation panel were installed against a basement wall, multiple narrow recesses could be provided to prevent water vapor from becoming trapped between the panel and the wall.

Referring again to FIG. 2, which depicts an embodiment suitable for use in attic insulation, the bottom surface 102 of the panel is substantially flat. A recess can be provided on the bottom surface 102 if necessary for the particular installation, but each recess reduces the effective thickness of the insulation panel and, thus, reduces its R-value.

The embodiment of the insulation panel shown in FIG. 2 also includes a breakaway slot 112. The breakaway slot 112 is a cut created partially through the depth of the insulation panel and is positioned about 16 inches from one edge 110 or 111 of the panel. Unlike the grooves 101, the breakaway slot 112 is narrow with a minimal gap between each side of the slot 112. The purpose of the breakaway slot 112 is to allow an installer to change the panel from a 24 inch wide panel to a 16 inch wide panel by simply folding the panel at the slot 112, causing the panel to fracture at the slot 112. In this particular example, a 24 inch wide insulation panel can be reduced to 16 inches if the installer encounters an area where 16 inch spacing is used between framing members and a 16 inch panel is not readily available. Additional breakaway slots 112 can be provided at other distances from the edges 110 and 111. Once fractured, the remaining portion of the panel can be used in other areas having reduced framing spacing or collected for recycling.

The rigid insulation panels can be manufactured in a variety of methods known in the art. As a person of ordinary skill will appreciate, rigid insulation products are often cut from a monolithic block of insulation. Manufacturers have the ability to mold these blocks with different densities and compositions. For example, lower grade products may include recycled insulation material. Manufacturers also have the ability to adjust the density of the rigid foam material to adjust the R-value and other physical properties. Depending on the sizes of the insulation panel, several panels can be cut from a single block. CNC-controlled hot wire cutters are one suitable way of cutting larger blocks into the desired shape. In other embodiments, the panels are shape molded; although, some cutting may be necessary when manufactured according to this method. In yet another embodiment, the panels are extruded.

The invention disclosed herein is not intended to be limited to the details disclosed. Rather, various modifications may be made in the details without departing from the invention. In addition, while the disclosure has been described in detail and with reference to specific embodiments, the embodiments are examples only. Thus, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. 

What is claimed is:
 1. A rigid insulation panel for installation between framing members, the insulation panel comprising: a panel body defined by a first edge, a second edge parallel to the first edge, and a pair of ends, wherein a thickness of the panel body is defined by a top surface and a bottom surface; and a groove extending partially through the thickness of the panel body from the top surface or the bottom surface, wherein the groove traverses the panel body between the pair of ends, wherein the groove is substantially parallel to the first edge and the second edge.
 2. The rigid insulation panel of claim 1, wherein the groove has an S-shaped profile when viewed from one end of the pair of ends.
 3. The rigid insulation panel of claim 1, wherein the groove comprises a first groove extending from the bottom surface.
 4. The rigid insulation panel of claim 3, further comprising a second groove extending from the top surface, wherein the first groove and the second groove are adjacent to each other.
 5. The rigid insulation panel of claim 1, wherein the first edge and the second edge are adapted to contact adjacent framing members.
 6. The rigid insulation panel of claim 1, wherein the panel is constructed from an insulation material selected from the group consisting of expanded polystyrene, extruded polystyrene, impregnated polystyrene, polyurethane, and polyisocyanurate.
 7. The rigid insulation panel of claim 1, wherein a distance between the first edge and the second edge is greater than a distance between the framing members.
 8. The rigid insulation panel of claim 7, wherein the groove collapses when installed between the framing members.
 9. The rigid insulation panel of claim 8, wherein the collapsed groove exerts an force towards the first edge and the second edge, thereby creating a friction fit with the framing members.
 10. The rigid insulation panel of claim 1, wherein the panel is resilient.
 11. The rigid insulation panel of claim 1, further comprising a chamfer disposed on the first edge and the second edge.
 12. The rigid insulation panel of claim 1, further comprising an air channel disposed on the top surface, wherein the air channel traverses the panel body between the pair of ends.
 13. The rigid insulation panel of claim 1, further comprising a breakaway slot extending partially through the thickness of the panel body from the top surface or the bottom surface between the pair of ends, wherein a force on the breakaway slot is capable of fracturing the panel along the breakaway slot to decrease a size of the panel.
 14. The rigid insulation panel of claim 1, wherein the panel is molded.
 15. The rigid insulation panel of claim 1, wherein the panel is cut from a monolithic block of insulation material.
 16. The rigid insulation panel of claim 1, wherein the panel is extruded. 